SoMerch

Branded packaging

Custom packaging that makes every delivery feel like part of the brand experience.

Frequently Asked Questions about Packaging

SoMerch produces custom outer boxes (rigid gift boxes, mailer boxes, shipping cartons), tissue paper, ribbons and bands, dust bags, custom inner inserts, gift sleeves, custom-printed tape, and unboxing cards. Packaging is designed to fit the kit it carries - sized to the items, sized to protect, and sized to fit standard EU shipping rates. Packaging is the first thing the recipient sees, so it does a lot of brand work. We design packaging in parallel with the items so the kit unboxes coherently rather than feeling assembled from unrelated parts. For onboarding programs, the box is often kept as a desk item after the kit is unpacked.

Yes, all three are produced in-house with full-color digital print or offset print for higher volumes. Boxes can be printed on the outside, inside, or both. Tissue paper accepts repeating-pattern prints in 1-2 colors. Mailer boxes (the corrugated kind for shipping) can carry full color on the outer faces and a printed design inside the lid. Inside-the-lid print is one of the highest-impact details - it's what the recipient sees first when opening the kit. Pattern-printed tissue paper adds another layer to the unboxing without adding meaningful cost. We mockup the full unboxing sequence at the design stage.

For kraft boxes, digital print and screen printing are the standard methods. Digital print handles full-color designs and is cost-effective at lower quantities. Screen printing produces a more saturated, premium-feeling print on natural kraft surfaces and is more economical at higher volumes (500+ units). Foil stamping is available for accent details like a logo or border. Kraft as a substrate is forgiving of simple, high-contrast designs; busy full-color art often reads better on white-coated boxes. For sustainability-focused brands, kraft plus a single-color print is the strongest pairing. We recommend method based on quantity, design, and brand voice.

Minimum order varies by packaging type. Custom rigid gift boxes typically start at 100 units. Mailer boxes start at 250-500 units due to die-cut tooling. Tissue paper and printed shipping tape start at 100 units. For pilot programs below these minimums, stock packaging with a custom sticker or band is the practical alternative. Setup costs for custom packaging (printing plates, die-cut tooling) make sub-100-unit runs uneconomical. For early programs, we recommend stock packaging plus a custom sticker, sleeve, or band - this captures most of the brand impact at a fraction of the setup cost.

Custom packaging production typically takes 10-15 business days after mockup approval - slightly longer than most other categories because of substrate prep and curing. EU shipping adds 2-6 business days. For onboarding programs, we produce packaging in batches aligned with item production so the full kit is ready to assemble at the same time. Tissue paper and printed tape are faster (around 8 business days). Custom die-cut rigid boxes or unusual structural designs can take 3+ weeks for the first run because of tooling. After tooling is made, repeat runs are faster.

Sustainable packaging options include FSC-certified paper and cardboard, recycled corrugated, kraft (uncoated, biodegradable), plant-based inks, paper-based void fill (replacing plastic), recyclable mono-material adhesives, and compostable tissue paper. Where possible, we eliminate plastic film and laminate finishes that complicate recycling. Sustainability is more than substrate - it's also about whether the recipient can recycle it locally. Mono-material kraft with paper tape is the easiest to recycle. Glossy laminated boxes look premium but mix substrates in ways that some recycling streams reject. We flag trade-offs at design.

Yes, packaging is typically co-designed around the kit contents - dimensions, weight, and protection needs. Our team designs the box to fit the items snugly (preventing rattle during shipping) and includes custom inserts where needed to immobilize fragile items. For multi-item kits, the box is sized to fit all items in one unbox without surplus volume. Right-sizing the packaging matters for shipping cost (volumetric weight) and unboxing experience (no items rattling, no excessive void fill). For variable kits (sizes differ by recipient), we design a base box with flex inserts that adapt to common variations.

Company kit packaging typically ranges from around €2-12 per unit at the 100-unit tier, depending on box type, print method, and inserts. A simple kraft mailer with a 1-color print sits at the lower end; a rigid full-color gift box with custom foam insert sits at the upper end. Pricing scales down meaningfully at 500+ units. Packaging spend is small relative to the items inside but does heavy lifting on perceived value. A €10 box around €40 of items lands very differently than a €2 mailer around the same items. We recommend the right packaging tier based on overall kit value and program intent.

Yes, kit assembly is done in-house. Items are folded, wrapped, paired, and packed into the outer kit packaging per a documented assembly spec. Each kit includes any inserts (welcome card, instructions, voucher codes) and is sealed with custom tape or band. Assembled kits are warehoused or shipped directly per your trigger. Assembly spec is locked at the kit design stage so every unit is identical. For multi-variant kits (different size apparel per recipient, different welcome card per region), the spec includes the variant logic and our team executes against it. Assembly is included in the kit quote.

Shipping cost across the EU is calculated on actual weight or volumetric weight (length x width x height / 5000), whichever is higher. Oversized or oddly-shaped packaging can push volumetric weight above actual weight, costing meaningfully more per shipment. Right-sized, flat-pack-when-empty design keeps shipping efficient. For multi-address kit programs (one kit per new hire to different countries), per-unit shipping cost is sensitive to box dimensions. A 5cm reduction in box height across 200 kits can save several hundred euros. We optimize dimensions at the design stage with this in mind.

Branded packaging

Branded packaging is the first thing a recipient experiences - before they see what's inside. The moment of picking up a box, reading it, and opening it is when the first impression of the program forms. A plain brown carton and a printed, considered box are two completely different experiences, even when the contents are identical. For companies that invest in onboarding kits, corporate gifts, or event packs, that moment matters.

The current range covers the core corporate use cases: three custom box formats sized and structured for the programs that run most often, alongside branded tape for the outer shipping layer. Everything is produced in-house, coordinated directly with kitting and assembly, and shipped to any EU address as part of a complete program or as standalone packaging stock.